Thermal decomposition of waste material

Abstract

A method and apparatus for the thermal decomposition of waste materials comprising an induction arc chamber having a thermal decomposed cavity formed therein and a plurality of electrode assemblies supported with the thermal decomposition cavity so that the electric arc gap formed between the electrode assemblies can be selectively varied to maintain a sufficiently high temperature in the thermal decomposition cavity to effect efficient decomposition of waste material in the induction arc chamber.

We claim: 
     
       1. An apparatus for thermal decomposition of waste materials comprising: an induction arc chamber having a waste inlet port, a residue outlet port and defining a thermal decomposition cavity therein;   electrode means supported within the thermal decomposition cavity for creating a high temperature turbulent zone within the thermal decomposition cavity when electrically energized, the electrode means having an electric arc gap which is selectively variable;   travel means operably connected to the electrode means for selectively maintaining the electric arc gap so that a sufficient high temperature is maintainable to decompose waste materials passed through the high temperature turbulent zone in the thermal decomposition cavity;   power means for electrically energizing the electrode means;   means for feeding waste materials into the thermal decomposition cavity via the inlet port;   means for receiving non-toxic particulate material discharged from the induction arc chamber through the residue outlet port; and   air lock means supported by the induction arc chamber for effectively sealing the inlet port and for preventing gases generated during the thermal decomposition of the waste materials from escaping through the inlet port.   
     
     
       2. An apparatus for thermal decomposition of waste materials comprising: an induction arc chamber having oppositely disposed electrode ports and defining a thermal decomposition cavity therein;   electrode means supported within the electrode ports of the induction arc chamber and extending into the thermal decomposition cavity for creating a high temperature turbulent zone within the thermal decomposition cavity when electrically energized, the electrode means having an electric arc gap which is selectively variable, the electrode means comprising: a first electrode assembly having a first electrode disposable within the thermal decomposition cavity and a second electrode assembly having a second electrode disposable within the thermal decomposition cavity such that the selectively variable electric arc gap is formed therebetween;   travel means operably connected to the electrode means for selectively maintaining the electric arc gap so that a sufficiently high temperature is maintainable to decompose waste materials passed through the high temperature turbulent zone in the thermal decomposition cavity;   power means for electrically energizing the electrode means; and   motor means operably connected to the first electrode for imparting rotation to the first electrode when the motor means is actuated.     
     
     
       3. An apparatus for thermal decomposition of waste materials comprising: an induction arc chamber defining a thermal decomposition cavity therein;   electrode means supported within the thermal decomposition cavity for creating a high temperature turbulent zone within the thermal decomposition cavity when electrically energized, the electrode means having a variable arc gap which is selectively variable, the electrode means comprising: first and second electrodes fabricated of carbon such that the second electrode further function as an additional fuel source for the induction arc chamber;   travel means operably connected to the first and second electrodes for selectively maintaining the electric arc gap so that a sufficiently high temperature is maintainable to decompose waste materials passed through the high temperature turbulent zone in the thermal decomposition cavity; and   D.C. power means for electrically energizing the first and second electrodes.     
     
     
       4. An apparatus for thermal decomposition of waste materials comprising: an induction arc chamber defining a thermal decomposition cavity therein;   electrode means supported within the thermal decomposition cavity for creating a high temperature turbulent zone within the thermal decomposition cavity when electrically energized, the electrode means having an electric arc gap which is relatively variable;   travel means operably connected to the electrode means for selectively maintaining the electric arc gap so that a sufficiently high temperature is maintainable to decompose waste materials passed through the high temperature turbulent zone in the thermal decomposition cavity;   power means for electrically energizing the electrode means; and   means for injecting a thermal enhancement gas into the high temperature turbulent thermal zone.   
     
     
       5. An apparatus for thermal decomposition of waste materials comprising: an induction arc chamber having at least two oppositely disposed electrode ports and defining a thermal decomposition cavity therein;   a first electrode assembly supported within one of the electrode ports and a second electrode assembly supported within the other electrode port so as to create a high temperature turbulent zone within the thermal decomposition cavity when electrically energized, the first and second electrode assemblies having an electric arc gap therebetween which is selectively variable, the first electrode assembly comprising: a first conducting member having a first end portion and an opposed second end portion; and   a first electrode supported on the first end portion of the first conducting member such that in an assemblied position the first electrode is disposed within the thermal decomposition cavity of the induction arc chamber and the opposed second end portion of the first conducting member extends outwardly from the induction arc chamber so as to be connectable to the power means and the travel means; and   the second electrode assembly comprising: a second conducting member having a first end portion and an opposed second end portion; and   a second electrode supported on the first end portion of the second conducting member such that in an assemblied position the second electrode is disposed within the thermal decomposition cavity of the induction arc chamber and the electric arc gap is formed between the first and second electrodes, the opposed second end portion of the second conducting member extending outwardly from the induction arc chamber;     travel means operably connected to the first and second conducting members for selectively maintaining the electric arc gap between the first and second electrodes so that a sufficiently high temperature is maintainable to decompose waste materials passed through the high temperature turbulent zone in the thermal decomposition cavity, the travel means comprising: a carriage means for supporting the first and second conducting members and for defining a travel path for the first and second conducting members so that the first and second conducting members can be reciprocally moved relative to each other;   step motor means connected to the carriage means for reciprocally moving the first and second conducting members upon actuation of the step motor means so as to selectively maintain the electric arc gap between the first and second electrodes; and   sensing and control means for determining the effective temperature in the high temperature turbulent zone and for producing a signal indication of such temperature so as to actuate the step motor means;     power means for electrically energizing the first and second electrodes; and   means for forming a substantially fluid-tight seal between the first and second conducting members and for cooling the first and second conducting members while permitting the first and second conducting members to be reciprocally moved relative to each other so that the electric arc gap formed between the first and second electrodes is selectively maintained.     
     
     
       6. An apparatus for thermal decomposition of waste materials comprising: an induction arc chamber having at least two oppositely disposed electrode ports and defining a thermal decomposition cavity therein;   electrode means for creating a high temperature turbulent zone within the thermal decomposition cavity when electrically energized, the electrode means having an electric arc gap which is selectively variable, the electrode means comprising: a first electrode assembly supported within one of the electrode ports and a second electrode assembly supported within the other of the electrode ports, the first electrode assembly comprising: a first tubular member fabricated of an electrical conductive material, the first tubular member having a first end portion, an opposed second end portion and a fluid flow passageway extending therebetween;   a first carbon electrode having a first end portion, an opposed second end portion and a fluid flow passageway extending therebetween, the first end portion having a substantially centrally disposed recessed portion formed therein and the opposed second end portion of the first carbon electrode connected to and supported by the first end portion of the first tubular member so that the fluid flow passageway of the first tubular member is in fluid communication with the fluid flow passageway of the first carbon electrode;   the second electrode assembly comprising: a second tubular member fabricated of an electrically conductive material, the second tubular member having a first end portion, an opposed second end portion and fluid flow passageway extending therebetween; and   a second carbon electrode having a first end portion, an opposed second end portion and a fluid flow passageway extending therebetween, the first end portion of the second carbon electrode configured to correspond with the centrally disposed recessed portion formed in the first end portion of the first carbon electrode such that the first end portion of the second carbon electrode is disposable within the recessed portion of the first carbon electrode to form the electric arc gap therebetween, the opposed second end portion of the second carbon electrode connected to and supported by the first end portion so that the fluid flow passageway of the second tubular member is in fluid communication with the fluid flow passageway of the second carbon electrode;     travel means operably connected to the first and second tubular members for selectively maintaining the electric arc gap between the first and second carbon electrodes so that a sufficiently high temperature is maintainable to decompose waste materials passed through the high temperature turbulent zone in the thermal decomposition cavity; and   power means for electrically energizing the first and second carbon electrodes.     
     
     
       7. A method for the thermal decomposition of waste material comprising the steps of: producing a high temperature zone of thermal turbulence within a thermal decomposition cavity of an induction chamber by electrical activation of at least one pair of electrodes extending therein and separated by a variable gap therebetween;   introducing the waste materials into the thermal decomposition chamber;   controlling the gap width between electrodes so that a sufficiently high temperature is maintained to substantially thermally decompose the waste material to form non-toxic products; and   introducing a thermal enhancement gas into the thermal decomposition cavity to enhance the temperature of the high temperature turbulence zone.   
     
     
       8. A method for the thermal decomposition of waste materials comprising the steps of: producing a high temperature zone of thermal turbulence within a thermal decomposition cavity of an induction arc chamber by electrical activation of at least one pair of electrodes extending therein and separated by a variable gap therebetween;   introducing the waste materials into the thermal decomposition cavity;   controlling the gap width between electrodes so that a sufficiently high temperature is maintained to substantially thermally decompose the waste material to form non-toxic products;   withdrawing particulate materials resulting from the thermal decomposition of the waste materials from the induction arc chamber;   separating gaseous vapors from the withdrawn particulate materials; and   rapidly cooling the gaseous vapors.   
     
     
       9. A method for the thermal decomposition of waste materials comprising the steps of: producing a high temperature zone of thermal turbulence within a thermal decomposition cavity of an induction arc chamber by electrical activation of at least one pair electrodes extending therein and separated by a variable gap therebetween;   introducing the waste materials into the thermal decomposition cavity;   controlling the gap width between electrodes so that a sufficiently high temperature is maintained to substantially thermally decompose the waste material to form non-toxic products;   measuring the energy requirements of the electrode to provide a signal representative thereof so as to actuate a travel assembly monitoring the temperature of the high temperature zone of thermal turbulence and utilizing such data to control the gap width between the electrodes.   
     
     
       10. The apparatus of claim 1 wherein the induction arc chamber is provided with a gas exhaust port and wherein the apparatus further comprises: cooling means in fluid communication with the induction arc chamber for receiving exhaust gases generated by the thermal decomposition of the waste materials in the thermal decomposition cavity and for rapidly cooling the gases prior to venting or subjecting such cooled gases to further processing.   
     
     
       11. The apparatus of claim 1 further comprising: valve means supported by the induction arc chamber for selectively opening and closing the residue outlet port.   
     
     
       12. The apparatus of claim 11 wherein the means for receiving non-toxic particulate material discharged from the induction arc chamber comprises auger means communicating with the residue outlet port for receiving the particulate materials from the thermal decomposition cavity via the residue outlet port. 
     
     
       13. The apparatus of claim 12 wherein the auger means is provided with a gas exhaust port and wherein the apparatus further comprises: cooling means operably connected to and in fluid communication with the gas exhaust port of the auger means for receiving exhaust gases therefrom and for cooling such exhaust gases to remove suspended particulate materials contained therein.   
     
     
       14. The apparatus of claim 13 further comprising: tower means connected to and in fluid communication with the cooling means for receiving the cooled exhaust gases; and   means for injecting neutralizing agents into the tower means to effectively neutralize the cooled exhaust gases.   
     
     
       15. The apparatus of claim 2 further comprising: second motor means operably connected to the second electrode assembly for imparting rotation to the second electrode when the second motor means is actuated.   
     
     
       16. The apparatus of claim 5 wherein the apparatus further comprises: means for sensing and determining the temperature of the high temperature turbulent zone and for actuating the travel means in response thereto.   
     
     
       17. The apparatus of claim 5 wherein the induction arc chamber is provided with a gas exhaust port and wherein the apparatus further comprises: cooling means in fluid communication with the induction arc chamber for receiving exhaust gases generated by the thermal decomposition of the waste materials in the thermal decomposition cavity and for rapidly cooling the gases prior to venting or subjecting such cooled gases to further processing.   
     
     
       18. The apparatus of claim 17 wherein the induction arc chamber is provided with a waste inlet port and a residue outlet port and wherein the apparatus further comprising: means for feeding waste materials into the thermal decomposition cavity via the inlet port; and   means for receiving non-toxic particulate material discharged from the induction arc chamber through the residue outlet port.   
     
     
       19. The apparatus of claim 18 further comprising air lock means supported by the induction arc chamber for effectively sealing the inlet port and for preventing gases generated during the thermal decomposition of the waste materials from escaping through the inlet port. 
     
     
       20. The apparatus of claim 19 further comprising valve means supported by the induction arc chamber for selectively opening and closing the residue outlet port. 
     
     
       21. The apparatus of claim 20 wherein the means for receiving non-toxic particulate material discharged from the induction arc chamber comprises auger means communicating with the residue outlet port for receiving the particulate materials from the thermal decomposition cavity via the residue outlet port. 
     
     
       22. The apparatus of claim 21 wherein the auger means is provided with a gas exhaust port and wherein the apparatus further comprises: cooling means operably connected to and in fluid communication with the gas exhaust port of the auger means for receiving exhaust gases and for cooling such exhaust gases to remove suspended particulate materials therefrom.   
     
     
       23. The apparatus of claim 22 further comprising: tower means connected to and in fluid communication with the cooling means for receiving the cooled exhaust gases; and   means for injecting neutralizing agents into the tower means to effectively neutralize the cooled exhaust gases.   
     
     
       24. The apparatus of claim 6 further comprising: cooling and sealing means for cooling the first and second conducting members when the first and second electrodes are electrically energized, the cooling and sealing means encompassing at least a portion of the first and second conducting members so as to form a substantially fluid-tight seal therebetween while permitting the first and second conducting members and thus the first and second electrodes to be reciprocally moved relative to one another upon actuation of the step motor means.   
     
     
       25. The apparatus of claim 24 further comprising means connectable to the opposed second end portion of the first tubular member for injecting fluid waste materials into the electric arc gap formed between the first and second carbon electrodes and into contact with the high temperature turbulent thermal zone. 
     
     
       26. The apparatus of claim 25 wherein the first carbon electrode is provided with a plurality of bores extending from its exterior surface to the fluid flow passageway of the first tubular member, the second carbon electrode is provided with at least one bore extending from its second end portion so as to openly communicate with the fluid flow passageway of the second tubular member, and wherein the apparatus further comprises: means connectable to the second end portion of the second tubular member for injecting a thermal enhancement fluid into the electric arc gap via the fluid flow passageway of the second tubular member and the bore of the second carbon electrode for enhancing the temperature of the high temperature turbulent thermal zone.   
     
     
       27. The method of claim 7 further comprising the step of: rapidly cooling gases exhausted from the thermal decomposition cavity to avoid formation of toxic byproducts during cooling of the gases and to separate suspended particulate materials therefrom.   
     
     
       28. The method of claim 8 further comprising: removing suspended particulate materials from the cooled gaseous vapors; and   neutralizing the particulate-free cooled gaseous vapors.   
     
     
       29. The method of claim 28 wherein the waste material is in the fluid state and the waste material is injected into the gap between the electrodes. 
     
     
       30. An apparatus for thermal decomposition of waste materials comprising: an induction arc chamber;   means for passing a thermal enhancement gas into the induction arc chamber;   electrode means supported within the induction arc chamber for creating a high temperature thermal zone when electrically energized, the electrode means having an electric arc gap which is selectively variable;   travel means operably connected to the electrode means for selectively maintaining the electric arc gap, the electrode means, the means for passing the thermal enhancement gas into the induction arc chamber and the travel means for selectively maintaining the electric arc gap cooperating to define a high temperature turbulent thermal zone in which a sufficiently high temperature is maintainable for a sufficient period of time to thermally decompose waste materials passed therethrough; and   power means for electrically energizing the electrode means.   
     
     
       31. The apparatus of claim 30 wherein the travel means comprises: carriage means for supporting the electrode means;   step motor means connected to the carriage means for imparting reciprocal movement to the electrode means so that the electric arc gap of the electrode means in selectively maintained; and   means for determining the temperature in the high temperature turbulent zone and for actuating the step motor means in response thereto.   
     
     
       32. The apparatus of claim 31 wherein the induction arc chamber is provided with a waste materials inlet opening and a residue outlet opening and wherein the apparatus further comprises: means for feeding waste materials into the induction arc chamber via the waste materials inlet opening; and   means for receiving non-toxic materials discharged from the induction arc chamber through the residue outlet port.   
     
     
       33. The apparatus of claim 31 wherein the induction arc chamber is provided with oppositely disposed electrode ports adapted to supportingly receive the electrode means and wherein the electrode means comprises a first electrode assembly having a first electrode extending inwardly into the thermal decomposition cavity and a second electrode assembly having a second electrode extending inwardly into the thermal decomposition cavity, the first and second electrodes being disposed opposite each other so that the electric arc gap is formed therebetween. 
     
     
       34. The apparatus of claim 33 further comprising: motor means operably connected to the first electrode assembly for imparting rotation to the first electrode when the motor means is actuated.   
     
     
       35. The apparatus of claim 34 further comprising: second motor means operably connected to the second electrode assembly for imparting rotation to the second electrode when the second motor means is actuated.   
     
     
       36. The apparatus of claim 31 wherein the induction arc chamber is provided with at least two oppositely disposed electrode ports and wherein the electrode means comprises a first electrode assembly supported within one of the electrode ports and a second electrode assembly supported within the other electrode port, the first electrode assembly comprising: a first conducting member having a first end portion and an opposed second end portion; and   a first electrode supported on the first end portion of the first conducting member such that in an assembled position the first electrode is disposed within the thermal decomposition cavity of the induction arc chamber and the opposed second end portion of the first conducting member extends outwardly from the induction arc chamber so as to be connectable to the power means and the travel means; and   the second electrode assembly comprising: a second conducting member having a first end portion and an opposed second end portion., and   a second electrode supported on the first end portion of the second conducting member such that in an assembled position the second electrode is disposed within the thermal decomposition cavity of the induction arc chamber and the electric arc gap is formed between the first and second electrodes, the opposed second end portion of the second conducting member extending outwardly from the induction arc chamber so as to be connectable to the power means and the travel means.     
     
     
       37. The apparatus of claim 36 further comprising: electrode cooling and sealing means for cooling the first and second conducting members when the first and second electrodes are electrically energized, the electrode cooling and sealing means encompassing a portion of the first and second conducting members so as to form a substantially fluid-tight seal therebetween while permitting the first and second conducting members and thus the first and second electrodes to be reciprocally moved relative to one another upon activation of the step motor means.   
     
     
       38. The apparatus of claim 37 wherein the apparatus is provided with a gas exhaust port for exhausting gases generated during the thermal decomposition of the waste material and wherein the apparatus further comprises: cooling means in fluid communication with the gas exhaust port for receiving gases exhausted through the gas exhaust port and for cooling the exhaust gases and for separating suspended particulate material present in the exhaust gases.   
     
     
       39. The apparatus of claim 38 wherein the induction arc chamber is provided with a waste inlet port and residue outlet port and wherein the apparatus further comprises: means for feeding waste materials into the thermal decomposition cavity via the inlet port; and   means for receiving non-toxic particulate material discharged from the induction arc chamber through the residue outlet port.   
     
     
       40. The apparatus of claim 39 wherein the means for receiving non-toxic particulate material discharged from the induction arc chamber comprises auger means communicating with the residue outlet port for receiving the particulate materials from the thermal decomposition cavity via the residue outlet port. 
     
     
       41. The apparatus of claim 40 further comprising valve means supported by the induction arc chamber for selectively opening and closing the residue outlet port. 
     
     
       42. The apparatus of claim 41 further comprising air lock means supported by the induction arc chamber for effectively sealing the inlet port and for preventing gases generated during the thermal decomposition of the waste material from escaping through the inlet port. 
     
     
       43. The apparatus of claim 42 wherein the gas exhaust port is provided in the auger means and wherein the apparatus further comprises: tower means connected to and in fluid communication with the cooling means for receiving the cooled gases; and   means for injecting neutralizing agents into the tower means to neutralize the cooled exhaust gases.